Butler NAV26HW.T Owner's manual

INSTRUCTION MANUAL

• For any further information please contact your local dealer or call:

For spare parts drawings refer to the section “ LIST OF COMPONENTS” enclosed to this manual.

GB

TRANSLATION FROM THE

ORIGINAL INSTRUCTIONS

- Rev. n. 7 (01/2017)

NAV26HW

NAV26HW.S

NAV26HW.ST

7503-M002-7_B

BUTLER ENGINEERING and MARKETING S.p.A. a s. u.

Via dell’Ecologia, 6 - 42047 Rolo - (RE) Italy

Phone (+39) 0522 647911 - Fax (+39) 0522 649760 - e-mail: Info@butler.it

7503-M002-7_B

INSTRUCTION, USE AND

MAINTENANCE MANUAL

GB

Page 2 of 68

7503-M002-6_B

NAV26HW - NAV26HW.S - NAV26HW.ST

SUMMARY

SYMBOLS USED IN THE MANUAL AND ON

THE MACHINE ___________________________ 6

1.0 GENERAL INTRODUCTION __________ 8

1.1 Introduction ____________________________ 8

2.0 INTENDED USE _____________________ 8

2.1 Training of personnel __________________ 8

3.0 SAFETY DEVICES ___________________ 9

4.0 GENERAL SAFETY RULES _________ 10

5.0 PACKING AND MOBILIZATION FOR

TRANSPORT _______________________ 11

6.0 UNPACKING ________________________ 11

7.0 MOBILIZATION _____________________ 11

8.0 MACHINE ASSEMBLY ______________ 12

8.1 Anchoring system _____________________12

8.2 Fixtures contained in the packing _____12

9.0 ELECTRICAL CONNECTIONS _______ 12

9.1 Oil check on oil-pressure power unit __13

9.2 Check of motor rotation direction _____13

9.3 Electrical checks ______________________13

10.0 WORKING ENVIRONMENT CONDI-

TIONS ______________________________ 14

10.1 Working position ______________________14

10.2 Working area __________________________14

10.3 Lighting _______________________________15

11.0 CONTROLS _________________________ 15

11.1 Control device (NAV26HW - NAV26HW.

ST) ____________________________________15

11.2 Control device (NAV26HW.S) ___________16

12.0 USING THE MACHINE ______________ 16

12.1 Precaution measures during tyre re-

moval and fitting ______________________16

12.2 Preliminary operations ________________17

12.3 Preparing the wheel ___________________17

12.4 Wheel clamping with self-centring

mandrel (NAV26HW - NAV26HW.S) _____17

12.5 Wheel clamping with locking ring nut

(NAV26HW.ST) _________________________18

12.6 Functioning of roll holder arm ________19

12.7 Tubeless tyres _________________________19

12.7.1 Bead breaking _____________________19

12.7.2 Demounting ________________________21

12.7.3 Mounting ___________________________23

12.8 Tyres with inner tube _________________25

12.8.1 Bead breaking _____________________25

12.8.2 Demounting ________________________25

12.8.3 Mounting ___________________________26

12.9 Wheels with bead wire ________________29

12.9.2 Mounting ___________________________30

13.0 ROUTINE MAINTENANCE __________ 31

14.0 TROUBLESHOOTING TABLE _______ 34

15.0 TECHNICAL DATA __________________ 36

15.1 NAV26HW technical data ______________36

15.2 NAV26HW.S technical data

_____________36

15.3 NAV26HW.ST technical data

___________36

15.4 Dimensions ____________________________37

16.0 STORING ___________________________ 40

17.0 SCRAPPING ________________________ 40

18.0 REGISTRATION PLATE DATA ______ 40

19.0 FUNCTIONAL DIAGRAMS __________ 40

Table A - Three-phase electric diagram

(NAV26HW - NAV26HW.ST) ________41

Table B - Electric diagram (NAV26HW.S)

____43

Table C - Oil-pressure diagram (NAV26HW)

_60

Table D - Oil-pressure diagram

(NAV26HW.S)

_____________________61

Table E - Oil-pressure diagram

(NAV26HW.ST)

____________________62

Table F - Single-phase electric diagram

(NAV26HW - NAV26HW.ST)

________63

Table G - Electric diagram (version with

inverter) (NAV26HW)

______________65

20.0 LIST OF COMPONENTS

INSTRUCTION, USE AND

MAINTENANCE MANUAL

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Page 3 of 68

KEY

1 - Main switch

2 - Grease holder ring

3 - Bead breaker roll

4 - Oil-pressure power unit

5 - Self-centring chuck

6 - Frame

7 - Bead breaker hook tool

8 - Demounting/mounting lever

9 - Bead breaker roll holder arm

10 - Grippers for alloy rims (on demand)

11 - Bead breaker tool/roll translation cylinder

12 - Tool holder arm locking pin

13 - Electric panel

14 - Mandrel rotation motor

15 - Mandrel opening/closing cylinder

16 - Control unit

17 - Bead breaker disc (G108A22, on demand)

18 - Assembly electrical box with inverter (version

with inverter)

19 - Roll unit with bead wires

7503-M002-6_B

NAV26HW - NAV26HW.S - NAV26HW.ST

FIG. 1 - NAV26HW

INSTRUCTION, USE AND

MAINTENANCE MANUAL

GB

Page 4 of 68

KEY

1 - Main switch

2 - Grease holder ring

3 - Bead breaker roll

4 - Oil-pressure power unit

5 - Self-centring chuck

6 - Frame

7 - Bead breaker hook tool

8 - Demounting/mounting lever

9 - Bead breaker roll holder arm

10 - Grippers for alloy rims (on demand)

11 - Bead breaker tool/roll translation cylinder

12 - Tool holder arm locking pin

13 - Electric panel

14 - Mandrel rotation motor

15 - Mandrel opening/closing cylinder

16 - Control unit

17 - Bead breaker disc (G108A22, on demand)

18 - Hydraulic controls version

19 - Roll unit with bead wires

7503-M002-6_B

NAV26HW - NAV26HW.S - NAV26HW.ST

FIG. 2 - NAV26HW.S

INSTRUCTION, USE AND

MAINTENANCE MANUAL

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Page 5 of 68

KEY

1 - Main switch

2 - Grease holder ring

3 - Bead breaker roll

4 - Oil-pressure power unit

5 - Self-centring chuck

6 - Frame

7 - Bead breaker hook tool

8 - Demounting/mounting lever

9 - Bead breaker roll holder arm

10 - Grippers for alloy rims (on demand)

11 - Bead breaker tool/roll translation cylinder

12 - Tool holder arm locking pin

13 - Electric panel

14 - Mandrel rotation motor

15 - Bead breaker disc (G108A22, on demand)

16 - Control unit

17 - Adapter for Dayton wheels (G108A21, on

demand)

18 - Cone kit for universal locking (G108A20, on

demand)

19 - Roll unit with bead wires

7503-M002-6_B

NAV26HW - NAV26HW.S - NAV26HW.ST

FIG. 3 - NAV26HW.ST

INSTRUCTION, USE AND

MAINTENANCE MANUAL

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Page 6 of 68

SYMBOLS USED IN THE MANUAL AND ON THE MACHINE

Symbols Description

B2167000

Read instruction manual.

FORBIDDEN!

Wear work gloves.

Wear work shoes.

B2167000

Wear safety earcaps.

99990758

Shock hazard.

999911770

Danger! Moving mechanical parts.

Caution: hanging loads.

Mandatory. Operations or jobs to

be performed compulsorily.

Danger! Be particularly careful.

Symbols Description

Move with fork lift truck or pallet

truck.

Lift from above.

B1541000

General danger.

Wear safety goggles.

Technical assistance necessary.

Do not perform any intervention.

999912860

Risk of limb crushing.

999912090

Danger: tyres could drop.

B6419000

Mandrel rotation index plate.

B2166000

Risk of hands crushing.

Risk of crushing and collisions.

Warning. Be particularly careful

(possible material damages).

Note. Indication and/or useful

information.

999912840

7503-M002-6_B

NAV26HW - NAV26HW.S - NAV26HW.ST

INSTRUCTION, USE AND

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Page 7 of 68

INFORMATION PLATE LOCATION TABLE

7503-M002-6_B

NAV26HW - NAV26HW.S - NAV26HW.ST

Code numbers of plates

B2166000 Hands crushing danger plate

B2167000 Obligation to wear protective clothing plate

B2668000 Wheel lifting device danger plate

B4219000 Rotation direction plate (NAV26HW - NAV26HW.ST)

B6419000 Rotation plate

99990644 Mandrel rotation index plate (NAV26HW - NAV26HW.ST)

99990758 Electricity danger plate

999912530 Single-phase voltage plate (NAV26HW - NAV26HW.ST)

999913010 Voltage plate 400V 50Hz 3Ph+N (version with inverter)(NAV26HW)

999916311 Rubbish skip label

999918381 Radio control label (NAV26HW.S)

* Machine nameplate

♦

Manufacturer name plate

IF ONE OR MORE PLATES DISAPPEAR FROM THE MACHINE OR BECOMES DIFFICULT

TO READ. REPLACE IT AND QUOTE ITS/THEIR CODE NUMBER/S WHEN REORDERING.

INSTRUCTION, USE AND

MAINTENANCE MANUAL

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Page 8 of 68

SOME OF THE PICTURES PRE-

SENT IN THIS MANUAL HAVE

BEEN OBTAINED FROM PICTURES

OF PROTOTYPES, THEREFORE

THE STANDARD PRODUCTION

MACHINES AND ACCESSORIES

CAN BE DIFFERENT IN SOME

COMPONENTS.

1.0 GENERAL INTRODUCTION

This manual is an integral part of the product and

must be retained for the whole operating life of the

machine.

Carefully study the warnings and instructions con-

tained in this manual. It contains important instruc-

tions regarding FUNCTIONING, SAFE USE and

MAINTENANCE.

KEEP THE MANUAL IN A KNOWN,

EASILY ACCESSIBLE PLACE FOR

ALL ACCESSORY OPERATORS

TO CONSULT IT WHENEVER IN

DOUBT.

THE MANUFACTURER DISCLAIMS

ALL RESPONSIBILITY FOR ANY

DAMAGE OCCURRED WHEN THE

INDICATIONS GIVEN IN THIS

MANUAL ARE NOT RESPECTED:

AS A MATTER OF FACT, THE NON-

COMPLIANCE WITH SUCH INDI-

CATIONS MIGHT LEAD TO EVEN

SERIOUS DANGERS.

1.1 Introduction

Thank you for preferring this electro-hydraulic tyre

changer. We feel sure you will not regret your decision.

This machine has been designed for use in profes-

sional workshops and in particular it stands out for

its reliability and easy, safe and rapid operation: with

just a small degree of maintenance and care, this tyre

changer will give you many years of trouble-free service

and lots of satisfaction.

7503-M002-6_B

NAV26HW - NAV26HW.S - NAV26HW.ST

2.0 INTENDED USE

The machines model “NAV26HW, NAV26HW.S

and NAV26HW.ST”, with relevant versions, are

tyre changers with electro-hydraulic working, to be

used only for the mounting and demounting of any

type of wheel with whole rim (with groove and bead

wire), with maximum dimensions of 1300 mm and

maximum weight of 1200 Kg.

The machines model “NAV26HW, NAV26HW.S and

NAV26HW.ST”, with relevant versions, are NOT to

be used for tyres inflation.

DANGER: THIS MACHINE MUST

BE USED STRICTLY FOR THE

INTENDED PURPOSE IT WAS

DESIGNED FOR (AS INDICATED

IN THIS MANUAL). ANY OTHER

USE WILL BE CONSIDERED IM-

PROPER USE. IN PARTICULAR

BEAD FITTING AND INFLATING

MUST BE CARRIED OUT IN A

SPECIALLY APPROVED INFLA-

TION CAGE.

THE MANUFACTURER CANNOT

BE HELD RESPONSIBLE FOR ANY

DAMAGE CAUSED BY IMPROPER,

ERRONEOUS, OR UNACCEPTABLE

USE.

AN INTENSIVE USE OF THE EQUIP-

MENT IN INDUSTRIAL ENVIRON-

MENT IS NOT RECOMMENDED.

2.1 Training of personnel

The machine may be operated only by suitably

trained and authorized personnel.

Given the complexity of the operations necessary to

manage the machine and to carry out the operations

safely and efficiently, the personnel must be trained

in such a way that they learn all the information

necessary to operate the machine as intended by the

manufacturer.

A CAREFUL READING OF THIS

INSTRUCTION MANUAL FOR

USE AND MAINTENANCE AND A

SHORT PERIOD OF TRAINING

WITH SKILLED PERSONNEL CAN

BE AN ENOUGH PREVENTIVE

PREPARATION.

INSTRUCTION, USE AND

MAINTENANCE MANUAL

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Page 9 of 68

7503-M002-6_B

NAV26HW - NAV26HW.S - NAV26HW.ST

3.0 SAFETY DEVICES

PERIODICALLY, AT LEAST MONTHLY, CHECK THE INTEGRITY AND THE FUNCTIONAL-

ITY OF THE SAFETY AND PROTECTION DEVICES ON THE MACHINE.

All the machines are equipped with:

• “man-operated” controls (immediate stop of operation when the control is released).

• Controls logic disposition

To prevent the operator from making dangerous mistakes;

• thermal magnetic switch on the supply line of the oil-pressure power unit motor: it avoids motor overheating

in case of intensive use (only for NAV26HW.S);

NO MODIFICATION OR CALIBRATION OF THE OPERATING PRESSURE OF THE MAXI-

MUM PRESSURE VALVE OR OF THE HYDRAULIC CIRCUIT PRESSURE LIMITER IS

PERMITTED

• controlled check valves on:

- opening of mandrel jaws (NAV26HW and NAV26HW.S),

- mandrel lifting,

- tool roll translation,

These valves have been fit in order to avoid unexpected movements of the jaws (and, as a consequence,

the wheel fall) (NAV26HW and NAV26HW.S), of the tool roll and locking mandrel, caused by accidental oil

drippings;

• fuses on the electric supply line of the mandrel motor;

• automatic power supply disconnection with the opening of the electric panel (only for NAV26HW.S).

• Fixed guards and shelters

The machine is fitted with a number of fixed guards intended to prevent potential crushing, cutting and

compression risks.

These protections can be located in the figure below.

Fig. 5

NAV26HW.S NAV26HW

NAV26HW.ST

INSTRUCTION, USE AND

MAINTENANCE MANUAL

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Page 10 of 68

3.1 Residual risks

The machine was subjected to a complete analysis of

risks according to reference standard EN ISO 12100.

Risks are as reduced as possible in relation with tech-

nology and product functionality.

This manual stresses possible residual risks, also

highlighted in pictograms on the present manual and

adhesive warning signals placed on the machine: their

location is represented in “PLATE LOCATION ON MA-

CHINE INFORMATION TABLE” on page 7.

4.0 GENERAL SAFETY RULES

• Any tampering with or modification to the machine

not previously authorized by the manufacturer ex-

empts the latter from all responsibility for damage

caused by or derived from said actions.

• Removing of or tampering with the safety devices or

with the warning signals placed on the machine leads

to serious dangers and represents a transgression of

European safety rules.

• Use of the machine is only permitted in places free

from explosion or fire hazard and in dry places

under cover.

• Original spare parts and accessories should be used.

THE MANUFACTURER DENIES

ANY RESPONSIBILITY IN CASE

OF DAMAGES CAUSED BY UNAU-

THORIZED MODIFICATIONS OR

BY THE USE OF NON ORIGINAL

COMPONENTS OR EQUIPMENT.

• Installation must be conducted only by qualified

personnel exactly according to the instructions that

are given below.

• Ensure that there are no dangerous situations dur-

ing the machine operating manoeuvres. Immediately

stop the machine if it miss-functions and contact the

assistance service of an authorized dealer.

• In emergency situations and before carrying out any

maintenance or repairs, disconnect all supplies to

the machine by using the main switch.

• The machine electrical supply system must be

equipped with an appropriate earthing, to which

the yellow-green machine protection wire must be

connected.

• Ensure that the work area around the machine is free

of potentially dangerous objects and that there is no

oil since this could damage the tyre. Oil on the floor

is also a potential danger for the operator.

OPERATORS MUST WEAR SUIT-

ABLE WORK CLOTHES, PROTEC-

TIVE GLASSES AND GLOVES,

AGAINST THE DANGER FROM

THE SPRAYING OF DANGEROUS

DUST, AND POSSIBLY LOWER

BACK SUPPORTS FOR THE LIFT-

ING OF HEAVY PARTS. DANGLING

OBJECTS LIKE BRACELETS MUST

NOT BE WORN, AND LONG HAIR

MUST BE TIED UP. FOOTWEAR

SHOULD BE ADEQUATE FOR THE

TYPE OF OPERATIONS TO BE CAR-

RIED OUT.

• The machine handles and operating grips must be

kept clean and free from oil.

• The workshop must be kept clean and dry. Make sure

that the working premises are properly lit.

The machine can be operated by a single operator.

Unauthorised personnel must remain outside the

working area, as shown in Fig. 11.

Avoid any hazardous situations. Do not use air-

operated or electrical equipment when the shop is

damp or the floor slippery and do not expose such

tools to atmospheric agents.

• When operating and servicing this machine, carefully

follow all applicable safety and accident-prevention

precautions.

The machine must not be operated by professionally

unskilled persons.

THE MACHINE OPERATES WITH

PRESSURIZED HYDRAULIC FLUID.

MAKE SURE EVERY COMPONENT

OF THE HYDRAULIC CIRCUIT IS

ALWAYS PROPERLY LOCKED, ANY

PRESSURIZED LEAKS MAY CAUSE

SERIOUS INJURIES OR WOUNDS.

IN CASE OF A CHANCE SUPPLY

FAILURE MOVE THE CONTROLS

TO THE NEUTRAL POSITION.

7503-M002-6_B

NAV26HW - NAV26HW.S - NAV26HW.ST

INSTRUCTION, USE AND

MAINTENANCE MANUAL

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Page 11 of 68

After removing the packing, and in the case of the ma-

chine packed fully assembled, check that the machine

is complete and that there is no visible damage. If in

doubt do not use the machine and refer to profession-

ally qualified personnel (to the seller). The packaging

components (plastic bags, expanded polystyrene, nails,

screws, pieces of wood, etc.) must be collected up and

disposed of through according to the in force laws.

THE BOX CONTAINING THE FIX-

TURES IS CONTAINED IN THE

WRAPPING. DO NOT THROW IT

AWAY WITH THE PACKING.

7.0 MOBILIZATION

THE LIFTING EQUIPMENT MUST WITHSTAND

A MINIMUM RATED LOAD EQUAL TO THE

WEIGHT OF THE MACHINE (SEE PARAGRAPH

TECHNICAL SPECIFICATIONS). DO NOT AL-

LOW THE LIFTED MACHINE TO SWING.

During the machine handling from the unpacking po-

sition to the installation one, follow the instructions

listed below.

• Protect the exposed corners with suitable material

(Pluribol/cardboard).

• Do not use metallic cables for lifting.

• Make sure that the electricity supply is not connected.

• Lift and transport with suitable device as indicated

in Fig. 7 (forks introduced in the middle to ensure

a correct loads distribution).

Fig. 7

7503-M002-6_B

NAV26HW - NAV26HW.S - NAV26HW.ST

5.0 PACKING AND MOBILIZATION FOR

TRANSPORT

HAVE THE MACHINE HANDLED BY SKILLED

PERSONNEL ONLY.

THE LIFTING EQUIPMENT MUST WITHSTAND

A MINIMUM RATED LOAD EQUAL TO THE

WEIGHT OF THE PACKED MACHINE (see para-

graph “TECHNICAL SPECIFICATIONS”).

The machine is packed completely assembled.

The cardboard box containing it is fastened to a

pallet and has dimensions of mm 1600x950x1780

(for NAV26HW - NAV26HW.S versions) and of mm

1950x950x1300 (for NAV26HW.ST version).

The displacement must be performed through ad-

equate lifting device (fork lift truck). Lift the packaging

as indicated in Fig. 6 (forks introduced in the middle

to ensure a correct loads distribution).

Fig. 6

6.0 UNPACKING

DURING UNPACKING, ALWAYS

WEAR GLOVES TO PREVENT ANY

INJURY CAUSED BY CONTACT

WITH PACKAGING MATERIAL

(NAILS, ETC.).

INSTRUCTION, USE AND

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Page 12 of 68

8.0 MACHINE ASSEMBLY

8.1 Anchoring system

The packed machine is fixed to the support pallet

through the holes prearranged on the frame. Such

holes can be used also to fix the machine to the ground,

through floor anchor small blocks (excluded from sup-

ply). Before carrying out the definitive fixing, check that

all the anchor points are laid down flat and correctly

in contact with the fixing surface itself. If not so, insert

shimming profiles between the machine and the fixing

lower surface, as indicated in Fig. 8.

Fig. 8

a= 1255 mm

b= 600 mm

• Execute 4 holes with 12 mm diameter on the floor

by the holes on the bottom floor;

• insert the small blocks (excluded from supply) into

the holes;

• fix the machine to the ground with 4 M12x120 mm

screws (excluded from supply) (Fig. 8 ref. 1) (or

with 4 12x80 mm stud bolts (excluded from supply)).

Tighten the screws with an approximate tightening

torque of 70 Nm.

8.2 Fixtures contained in the packing

The packing case contains also the fixtures box.

Check that all the parts listed are there.

Code Description N.

G108A3 Head with lever 1

G108A41 Unit roll with bead wire 1

7503-M002-6_B

NAV26HW - NAV26HW.S - NAV26HW.ST

9.0 ELECTRICAL CONNECTIONS

EVEN THE TINIEST PROCEDURE

OF AN ELECTRICAL NATURE

MUST BE CARRIED OUT BY PRO-

FESSIONALLY QUALIFIED STAFF.

BEFORE CONNECTING THE MA-

CHINE MAKE SURE THAT:

• THE MAIN POWER RATING COR-

RESPONDS TO THE MACHINE

RATING AS SHOWN ON THE

MACHINE PLATE;

• ALL MAIN POWER COMPO-

NENTS ARE IN GOOD CONDI-

TION;

• THE ELECTRICAL SYSTEM

IS PROPERLY GROUNDED

(GROUND WIRE MUST BE THE

SAME CROSS-SECTION AREA

AS THE LARGEST POWER SUP-

PLY CABLES OR GREATER);

• MAKE SURE THAT THE ELEC-

TRICAL SYSTEM FEATURES A

CUTOUT WITH DIFFERENTIAL

PROTECTION SET AT 30 mA.

The machines (NAV26HW and NAV26HW.ST) are

supplied with free cable of mt. 1,8 while the machine

(NAV26HW.S) is supplied with free cable of mt. 5,8.

A plug corresponding to the following requirements

must be connected to the cable:

• Conformity to Norm IEC 309

• 230 Volt – 16A

• 2P + Ground

• IP 44

Only for VARGNAV26HWD - version with inverter

• Conformity to Norm IEC 309

• 185 Volt – 32A

• 3P + N + Ground

• IP 44

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Page 13 of 68

Only for 230V 60Hz 1Ph version

• Conformity to Norm IEC 309

• 230 Volt - 60Hz – 32A

• 1P + N + Ground

• IP 44

FIT A TYPE-APPROVED PLUG

TO THE MACHINE CABLE (THE

GROUND WIRE IS YELLOW/GREEN

AND MUST NEVER BE CONNECT-

ED TO THE PHASE LEADS).

MAKE SURE THAT THE ELECTRI-

CAL SYSTEM IS COMPATIBLE

WITH THE RATED POWER AB-

SORPTION SPECIFIED IN THIS

MANUAL AND APT TO ENSURE

THAT VOLTAGE DROP UNDER

FULL LOAD WILL NOT EXCEED

4% OF RATED VOLTAGE (10%

UPON START-UP).

FAILURE TO OBSERVE THE ABOVE

INSTRUCTIONS WILL IMMEDIATE-

LY INVALIDATE THE WARRANTY.

9.1 Oil check on oil-pressure power unit

THE OIL-PRESSURE POWER UNIT

IS DELIVERED WITHOUT HY-

DRAULIC OIL, THEREFORE MAKE

SURE THE TANK PROVIDED IS

FILLED WITH OIL WITH VISCOS-

ITY DEGREE APPROPRIATE TO

THE AVERAGE TEMPERATURES

IN THE INSTALLATION COUNTRY

AND IN PARTICULAR:

- VISCOSITY 32 (FOR COUNTRIES

WITH ROOM TEMPERATURE

FROM 0 TO 30 DEGREES);

- VISCOSITY 46 (FOR COUNTRIES

WITH ROOM TEMPERATURE

ABOVE 30 DEGREES).

9.2 Check of motor rotation direction

Once the last electrical connection has been termi-

nated, power the machine with the main switch.

Make sure the motor of the hydraulic power unit ro-

tates in the direction indicated by the arrow (Fig. 9 and

10 pos. B) visible on the electric motor cap.

7503-M002-6_B

NAV26HW - NAV26HW.S - NAV26HW.ST

If rotation should occur in the opposite direction, the

machine must be immediately stopped and phase in-

version must be executed inside the plug connection

in order to reset the correct rotation direction.

FAILURE TO OBSERVE THE ABOVE

INSTRUCTIONS WILL IMMEDIATE-

LY INVALIDATE THE WARRANTY.

9.3 Electrical checks

BEFORE STARTING UP THE TYRE-

CHANGER, BE SURE TO BECOME

FAMILIAR WITH THE LOCATION

AND OPERATION OF ALL CON-

TROLS AND CHECK THEIR PROP-

ER OPERATION (SEE PAR. “CON-

TROLS”).

CARRY OUT A DAILY CHECK OF

MAINTAINED-TYPE CONTROLS

CORRECT FUNCTIONING, BEFORE

STARTING MACHINE OPERATION.

Once the plug/socket connection has been made, turn

on the machine using the master switch (Fig. 9 and

10 pos. A).

NAV26HW.S

Fig. 9

KEY

A - Main switch

B - Direction rotation of oil-pressure power unit

motor

INSTRUCTION, USE AND

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Page 14 of 68

10.0 WORKING ENVIRONMENT CONDI-

TIONS

The machine must be operated under proper condi-

tions as follows:

• temperature: 0° + 55° C

• relative humidity 30 - 95% (dew-free)

atmospheric pressure: 860 - 1060 hPa (mbar).

The use of the machine in ambient conditions other

than those specified above is only allowed after prior

agreement with and approval of the manufacturer.

10.1 Working position

In Fig. 11 it's possible to define working positions A,

B, C which will be referred to in the description of

machine operative phases.

Positions A and B must be considered as main posi-

tions for tyre mounting and demounting and for wheel

clamping on the mandrel, while positions A and C are

the best positions to follow tyre bead breaking and

demounting operations.

Working in these positions allows better precision and

speed during operating phases as well as greater safety

for the operator.

10.2 Working area

Fig. 11

INSTALL THE MACHINE INDOORS OR IN A

ROOFED AREA. PLACE OF INSTALLATION

MUST BE DRY, ADEQUATELY LIT AND IN

COMPLIANCE WITH APPLICABLE SAFETY

REGULATIONS.

7503-M002-6_B

NAV26HW - NAV26HW.S - NAV26HW.ST

Then horizontally or vertically move the lever (Fig. 13

pos. E): the red LED (Fig. 13 pos. B) will flash.

Wait a few seconds for the green LED to turn on (Fig.

13 pos. A) and then release the lever (Fig. 13 pos. H).

In the end, the green LED (Fig. 13 pos. A) flashes to

indicate that the machine is ready for operation.

WHEN A CONTROL IS OPERATED,

THE GREEN LED (FIG. 13 POS.

A) LIGHT IS FIXED: IT FLASHES

AGAIN WHEN IT IS RELEASED.

If during the operations the red LED (Fig. 13 pos. B)

and the green LED (Fig. 13 pos. A) turn on at the same

time, charge the control batteries with the provided

socket for battery charger, located on the control side

(Fig. 13 pos. G).

The machine is equipped with a device for the interrup-

tion of the communication between the control and the

electrical panel, when more than 6 hours have passed

after the last executed control. In this case, just repeat

the turning on operations described in the “Electrical

checks” chapter.

NAV26HW - NAV26HW.ST

KEY

A - Main switch

B - Direction rotation of oil-pressure power unit

motor

C - Selector 1-0-2 self-centring chuck speed con-

trol (only for VARGNAV26HWD - version with

inverter)

Fig. 10

ONCE THE ASSEMBLY OPERA-

TIONS HAVE BEEN ENDED, CHECK

ALL MACHINE FUNCTIONS.

INSTRUCTION, USE AND

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Page 15 of 68

The use of the machine requires a usable space of

mm 5000x5000, (as indicated in Fig. 11). The use of

the machine must respect the shown distances. From

the control position the operator is able to observe all

the machine and surrounding area. He must prevent

unauthorized personnel or objects that could be dan-

gerous from entering the area.

The machine must be preferably used on an horizontal

floor. Avoid yielding or irregular surfaces.

The base floor must be able to support the loads

transmitted during operation. This surface must have

a capacity load of at least 500 kg/m².

The depth of the solid floor must be sufficient to guar-

antee that the support feet rest safely.

10.3 Lighting

The machine does not require its own lighting for

normal working operations. However, it must be used

in an adequately lit environment.

In case of poor lighting use lamps having total power

of 800/1200 Watt.

7503-M002-6_B

NAV26HW - NAV26HW.S - NAV26HW.ST

11.0 CONTROLS

11.1 Control device (NAV26HW - NAV26HW.

ST)

The control (handle control) can be moved according

to the positioning necessities of the operator.

MAKE SURE THERE ARE NO PER-

SONS OR OBJECTS HIDDEN TO

THE OPERATOR VISUAL FIELD

BY THE WHEEL SIDE PLAY (ESPE-

CIALLY IN CASE OF WHEELS WITH

LARGE DIMENSIONS).

The control (Fig. 12) consists of:

• “A” lower selector (with guard) for wheel holder

mandrel open/close control with three positions:

one central position “stable” to stop mandrel open/

close movement and two positions “with maintained

control” to open/close mandrel jaws (NAV26HW);

• “B” lever for tool holder tool/bead breaking roll

translation control with three-positions: one central

position “stable” to stop translation and two positions

“with maintained control” for tool/bead breaking roll

support translation rightwards or leftwards (from

working position “C”

Fig. 11

);

• “C” lever three-positions control for vertical trans-

lation of mandrel arm: central “firm” position for

movement stop and two “hold activation” positions

for arm up and down translation;

• “D” lever control mandrel anticlockwise/clockwise

rotation.

Fig. 12

INSTRUCTION, USE AND

MAINTENANCE MANUAL

GB

Page 16 of 68

Fig. 13

12.0 USING THE MACHINE

12.1 Precaution measures during tyre re-

moval and fitting

Before fitting a tyre, observe the following safety rules:

• always use clean, dry and in good condition rims

and tyres; in particular, if necessary, clean the rims

after all the balancing weights (as well as the adhesive

weights on the inner side) have been removed, and

make sure that:

- neither the bead nor the tread of the tyre are dam-

aged;

- the rim does not produce dents and/or deformation

(especially for alloy rims, dents can cause internal

micro-fractures, that pass unobserved at visual

inspection, and can compromise the solidity of the

rim and constitute danger even during inflation);

• adequately lubricate the contact surface of rim and

tyre bead, using specific tyre lubricants only;

• replace the inner tube valve with a new valve, if the

tyre tube has a metal valve, replace the grommet;

• make sure that the tyre is the right size for the rim;

on the contrary, never fit a tyre unless you are sure

it is the right size (the rated size of the rim and tyre

is usually printed directly on each of them);

• do not use compressed air or water jets to clean the

wheels on the machine.

7503-M002-6_B

NAV26HW - NAV26HW.S - NAV26HW.ST

11.2 Control device (NAV26HW.S)

The control unit (handle control), thanks to special

belts, can be fixed to the operator’s body, so that it

follows him and stays within reach during all the pro-

duction phases.

It is advisable for the operator to place himself in a

zone free from obstacles in order to have a clear and

complete vision of the working area.

MAKE SURE THERE ARE NO PER-

SONS OR OBJECTS HIDDEN TO

THE OPERATOR VISUAL FIELD

BY THE WHEEL SIDE PLAY (ESPE-

CIALLY IN CASE OF WHEELS WITH

LARGE DIMENSIONS).

The flashing green led “A”, indicates the machine

stand-by position. When any control is operated, the

machine is started and it is ready for operation. Dur-

ing functioning, the green led “A” is turned on with a

fixed light.

The simultaneously turned on and flashing led “B”

and led “A” indicate that the manipulator batteries are

exhausted: in order to carry on the functioning, they

must be charged.

IN ORDER TO ACTIVATE THE COM-

MUNICATION BETWEEN HANDLE

CONTROL AND MACHINE, ON MA-

CHINE SWITCHING AND AFTER

EACH POSITIONING IN STAND-BY

MODE, IT'S NECESSARY TO OPER-

ATE ANY JOYSTICK (LEVER “H”

OR LEVER “I”) FOR 5 SECONDS

AT LEAST.

When the red led“B” lights up indicates that there is

a fault in the bluetooth connection with the machine.

“Push-button C” has one “hands-on” operating posi-

tion, and when pressed, it opens the self-centring

chuck.

“Push-button D” has one “hands-on” operating posi-

tion, and when pressed, it closes the self-centring

chuck.

“Lever E” has four “hands-on” positions:

- Lever to the right or left: it starts the travel of the

bead breaking roll/tool to the right or left respectively

(from “B” working position, Fig. 11).

- Upwards or downwards lever: it respectively lifts or

lowers the mandrel.

“Lever F” has two “hands-on” positions:

- Lever to the right or left, operates the clockwise or

counterclosckwise rotation of the mandrel (from

working position “A” Fig. 11).

When any control is operated, the machine is started

again, ready for operation: led “A” flashes.

THE HANDLE CONTROL MUST

NOT BE PLACED WHERE WATER

STAGNATES.

INSTRUCTION, USE AND

MAINTENANCE MANUAL

GB

Page 17 of 68

Fig. 14

Clamping on the central hole

Fig. 15

Clamping on bead seat

OPENING/CLOSING MOVEMENT

OF THE SELF-CENTRING MAN-

DREL CAN GENERATE DANGER

OF SQUASHING, CUTTING, COM-

PRESSING. DURING WHEEL

LOCKING/UNLOCKING PHASE,

AVOID THAT PARTS OF HUMAN

BODY COME INTO CONTACT WITH

MOVING PARTS OF THE MACHINE.

7503-M002-6_B

NAV26HW - NAV26HW.S - NAV26HW.ST

12.2 Preliminary operations

In view of the tyre changer structure and of its intended

use, the operator must work with wheels with large

diameter (up to 2550 mm) and with remarkable weight

(up to 2300 kg).

The utmost care while moving the wheels is recom-

mended: make use of other operators, properly trained

and with suitable clothes.

THE CAREFUL LUBRICATION OF THE TYRES

BEADS IS RECOMMENDED, IN ORDER TO PRO-

TECT THEM FROM POSSIBLE DAMAGES AND

TO FACILITATE MOUNTING AND DEMOUNTING

OPERATIONS.

12.3 Preparing the wheel

• Remove the wheel balancing weights from both sides

of the wheel.

REMOVE THE VALVE STEM AND

ALLOW THE TYRE TO COMPLETE-

LY DEFLATE.

• Establish from which side the tyre should be de-

mounted, checking the position of the groove.

• Find the rim locking type.

12.4 Wheel clamping with self-centring

mandrel (NAV26HW - NAV26HW.S)

FOR WHAT CONCERNS THE DI-

MENSIONS AND WEIGHT OF THE

WHEEL TO BE LOCKED, MAKE

USE OF A SECOND OPERATOR

WHO MUST HOLD THE WHEEL

INTO VERTICAL POSITION, IN

ORDER TO ENSURE SAFE OPERA-

TIVE CONDITIONS.

When handling wheels weighing more than 500 Kg a

fork-lift truck or a crane should be used.

MAKE SURE THAT RIM CLAMPING

IS DONE PROPERLY AND THAT

THE GRIP IS SAFE, TO PREVENT

THE WHEEL FROM FALLING DUR-

ING MOUNTING OR REMOVAL

OPERATIONS.

DO NOT CHANGE THE SET OP-

ERATING PRESSURE VALUE BY

MEANS OF THE MAXIMUM PRES-

SURE VALVES. THE MANUFAC-

TURER SHALL NOT BE RESPON-

SIBLE FOR INJURY OR DAMAGE

ARISING FROM UNAUTHORISED

CHANGES.

INSTRUCTION, USE AND

MAINTENANCE MANUAL

GB

Page 18 of 68

All wheels must be clamped from the inside.

Clamping on the central flange is always safest.

NOTE: for wheels with grooved rims secure the

wheel so the groove is facing outward compared to

the mandrel.

If it is not possible to clamp the rim in the hole of the

disc, clamp on the bead seat close to the disc.

TO SECURE WHEELS WITH ALLOY

RIMS ADDITIONAL PROTECTIVE

JAWS ARE AVAILABLE. THEY AL-

LOW YOU TO WORK ON THE RIMS

WITHOUT DAMAGING THEM. THE

PROTECTIVE JAWS ARE FITTED

ONTO THE MANDREL’S NORMAL

JAWS BY MEANS OF A BAYONET

CONNECTION.

To clamp the wheel proceed as follows:

- Place the wheel in vertical position not far from the

mandrel;

- Use the lever (Fig. 12 pos. C) or (Fig. 13 pos. E) to

position the coaxial mandrel with the wheel centre,

in order to make the jaws edges skim the wheel edge;

- Adjust the opening of the self-centring mandrel

through the corresponding control (Fig. 12 pos. A)

or (Fig. 13 pos. C) according to the type of rim to

be locked;

- Operate the control (Fig. 12 pos. A) or (Fig. 13 pos.

C) until the wheel is completely clamped.

- Check both that the rim is clamped and centred

correctly, and that the wheel has been raised above

from the floor, so that it does not slip during the

operations which follow.

KEEP ON OPERATING RIM CLAMP-

ING CONTROL, UNTIL REACHING

THE MAXIMUM OPERATING PRES-

SURE (130 BAR).

THE CAREFUL LUBRICATION OF THE TYRES

BEADS IS RECOMMENDED, IN ORDER TO PRO-

TECT THEM FROM POSSIBLE DAMAGES AND

TO FACILITATE MOUNTING AND DEMOUNTING

OPERATIONS.

AFTER COMPLETION OF TYRE

MOUNT/DEMOUNT OPERATIONS

DO NOT LEAVE THE WHEEL

CLAMPED ON THE SELF-CEN-

TRING CHUCK AND NEVER LEAVE

IT UNATTENDED ANYWAY.

7503-M002-6_B

NAV26HW - NAV26HW.S - NAV26HW.ST

12.5 Wheel clamping with locking ring nut

(NAV26HW.ST)

FOR WHAT CONCERNS THE DI-

MENSIONS AND WEIGHT OF THE

WHEEL TO BE LOCKED, MAKE

USE OF A SECOND OPERATOR

WHO MUST HOLD THE WHEEL

INTO VERTICAL POSITION, IN

ORDER TO ENSURE SAFE OPERA-

TIVE CONDITIONS.

When handling wheels weighing more than 500 Kg a

fork-lift truck or a crane should be used.

MAKE SURE THAT RIM CLAMPING

IS DONE PROPERLY AND THAT

THE GRIP IS SAFE, TO PREVENT

THE WHEEL FROM FALLING DUR-

ING MOUNTING OR REMOVAL

OPERATIONS.

Fig. 16

To clamp the wheel proceed as follows:

- Place the wheel in vertical position not far from the

mandrel;

Use the lever (Fig. 12 pos. C) to position the coaxial

mandrel with the wheel centre, so that the threaded

pin is placed at the same height of the central hole

of the rim;

- Insert the rim on the threaded pin (and the well

placed outwards);

- Lock the rim on the mandrel by using the star flange

(Fig. 16 pos. 1) and make sure that drive pin goes

into the right hole for the tyre;

INSTRUCTION, USE AND

MAINTENANCE MANUAL

GB

Page 19 of 68

- Lock the wheel on the centring flange using the ring

nut (Fig. 16 pos. 2). Through the special small and

inner levers (Fig. 16 pos. 4) unlock the ring nut

and move it close to the star flange (Fig. 16 pos. 1),

therefore rotate the ring nut (Fig. 16 pos. 2) through

the external levers (Fig. 16 pos. 3) until the complete

flange clamping (Fig. 16 pos. 1) on the tyre;

- Check both that the rim is clamped and centred

correctly, and that the wheel has been raised above

from the floor, so that it does not slip during the

operations which follow.

THE CAREFUL LUBRICATION OF THE TYRES

BEADS IS RECOMMENDED, IN ORDER TO PRO-

TECT THEM FROM POSSIBLE DAMAGES AND

TO FACILITATE MOUNTING AND DEMOUNTING

OPERATIONS.

AFTER COMPLETION OF TYRE

MOUNT/DEMOUNT OPERATIONS

DO NOT LEAVE THE WHEEL

CLAMPED ON THE SELF-CEN-

TRING CHUCK AND NEVER LEAVE

IT UNATTENDED ANYWAY.

12.6 Functioning of roll holder arm

During the working phases, the roll holder arm can

maintain two firm positions, that is:

1) “Working” position;

2) “Out of work” position.

In “working” position (Fig. 17 pos. 1) the tool holder

arm is lowered towards the mandrel and from this

position it executes the various tyre bead breaking,

demounting and mounting operations.

Fig. 17

7503-M002-6_B

NAV26HW - NAV26HW.S - NAV26HW.ST

In “out of work” position (Fig. 18 pos. 1) the roll holder

arm is in horizontal position and has to be brought in

this position every time it is not in use and in order to

be shifted from one tyre bead side to another, during

working phases.

Fig. 18

The roll holder arm, shifts from “off-work” position to

“working” position and vice versa manually.

IN “WORKING POSITION” OR

“OUT OF WORK POSITION”, THE

SAFETY PIN (FIG. 1 POS. 12) HAS

TO BE INSERTED INTO THE AP-

PROPRIATE HOUSING.

12.7 Tubeless tyres

12.7.1 Bead breaking

NEVER PLACE ANY PART OF

YOUR BODY BETWEEN THE BEAD

BREAKER ROLL AND THE TYRE.

THROUGHOUT TYRE MOUNT-

ING/DEMOUNTING OPERATIONS,

CHECK THAT THE SELF-CENTRING

MANDREL CLAMPING PRESSURE

IS CLOSE TO THE MAXIMUM

OPERATING VALUE (130 BAR)

(NAV26HW - NAV26HW.S).

INSTRUCTION, USE AND

MAINTENANCE MANUAL

GB

Page 20 of 68

A. Lock the wheel on the mandrel as described in the

previous paragraph.

B. Remove all balancing weights from the rim. Extract

the valve and let air out of tyre.

C. Move to work position A (Fig. 11).

D. Position the beading disc on the external side of

the tyre.

ALWAYS VERIFY THAT THE ARM

IS CORRECTLY LOCKED TO THE

SHIFTING BEAM.

E. Lift the mandrel (Fig. 19 pos. 1) by using the ap-

propriate handle control, until bringing the beading

disc (Fig. 19 pos. 2) next to the tyre brim (Fig. 19

pos. 3), in contact with the external bead.

Fig. 19

THE BEADING ROLL MUST NOT

EXERT PRESSURE ON THE RIM

BUT ON THE TYRE

BEAD

F.

Turn the mandrel counterclockwise and, at the

same time, gradually move the roll (Fig. 20 pos.

1) inwards to bead the tyre. Continue to turn the

mandrel while generously lubricating the tyre rim

and bead with a suitable lubricant.

The more the wheel adheres to the rim, the slower

should the beading roll advance.

Fig. 20

USE ONLY TYRE LUBRICANTS.

SUITABLE LUBRICANTS CONTAIN

NO WATER, HYDROCARBONS, OR

SILICON.

G. Once external beading has been carried out, unhook

and lift the roll holder arm placing it in “off-work”

position (Fig. 18 pos. 1); use the handle control

to position the roll holder arm on the inner side of

the wheel, then place it in “work position” (Fig. 17

pos. 1) and secure it with the special safety pin.

FOR WHEELS WITH MAX. DIAM-

ETER LOWER THAN 1100 MM, IT

IS POSSIBLE TO SHIFT THE BEAD-

ING ROLL INTO THE SAME REAR

BEADING POSITION BY LOWER-

ING THE WHEEL (SEE FIG. 21)

IN ORDER TO BRING IT BACK TO

BEADING POSITION (SEE FIG. 22).

Fig. 21

7503-M002-6_B

NAV26HW - NAV26HW.S - NAV26HW.ST

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